Dispensing applicator



May 19, 1964 Filed March 30, 1962 G. D. MILES DISPENSING APPLICATOR 2 Sheets-Sheet 1 lhilVENTOR GILBERT DEWAYNE MILES 5 ATTORNY May 19, 1964 G. D. MILES 3,133,309

DISPENSING APPLICATOR Filed March 30, 1962 2 Sheets-Sheet 2 INVENTOR GILBERT DEWAYNE MILES ATTORNEY United States Patent 3,133,309 DISPENSING APPLICATOR Gilbert Dewayne Miles, Ossining, N.Y., assignor to Colgate-Palmolive Company, New York, N.Y., a corporation of Delaware Filed Mar. 30, 1962, Ser. No. 186,588 22 Claims. (Cl. 15-565) This invention relates to a dispensing applicator primarily intended for applying liquids to epidermal surfaces. The invention includes novel applicator structures, fitments, materials and processes of applying liquids.

The present applicators are especially useful for conveniently applying aqueous and alcoholic liquids, such as shaving lotions (including those used before, as well as after shaving), antiperspirants, deodorants and germicides to the skin but may also be employed suitably to dispense and apply other liquids to other surfaces.

The objects of the invention, its advantages, various embodiments, equivalents and features thereof will be apparent from the following description, taken together with the illustrations in which:

FIG. 1 is a partially cut away front elevational view of an assembled dispensing applicator, omitting pant of the container;

FIG. 2 is a disassembled view, in front elevation, of the component parts of an applicator fitment, omitting container and closure;

FIG. 3 is a top plan view of the applicator fitment of FIG. 2;

FIG. 4 is a central vertical sectional view of the same applicator fitment;

FIG. 5 is a top plan view of a variation of the applicator fitment;

FIG. 6 is a central vertical section of the fitment, taken along plane 66;

FIG. 7 is a central vertical section of another fitment, similar to that of FIG. 6;

FIG. 8 is a disassembled view of another applicator assembly within the invention;

FIG. 9 is a top plan view of the container of FIG. 8;

FIG. 10 is a central vertical section of the neck portion of that container;

FIG. 11 is a top plan view of the applicator in position on the container, the closure being omitted;

FIG. 12 is a central vertical sectional view of the fitment of FIGS. 8 and 11;

FIG. 13 is an enlarged top plan view of a portion of the fitment of FIGS. 11 and 12;

FIG. 14 is an enlarged partial central vertical sectional View of a variation of applicator fitment;

FIG. 15 is a top plan view of another form of dispensing applicator within the scope of the invention; and

FIG. 16 is a partial central vertical section of the applicator of FIG. 15.

In the applicator shown in FIGS. 14, numeral 11 designates a container, usually glass or plastic, having a neck 13, in which walls 15 define an opening 17. EX- ternal screw thread 19 on neck 13 is suitable for engagement with an internally threaded closure member. At the top 20 of the threaded neck of the container, on the inside, is an inwardly extending flange or head 21 of lesser diameter than the rest of the neck wall that defines the container opening.

A flanged cup 23 of resilient plastic material, such as polyethylene, has a flange 25 at the top thereof, sloping side walls 27 flaring outwardly and a bottom 29 containing an opening 31 to allow the passage of liquid contents from container 11 to cup 23. Inside cup 23 is a resilient open celled plastic foam sponge 35, such as polyurethane foam, which, in its relaxed state, under use conditions is preferably of size greater than the cup volume. Atop the sponge 35 is a cover member 37 which allows the passage of liquid. As shown, it contains a multiplicity of openings 39 distributed over its upper surface. As illustrated, this cover member is a cloth of synthetic thermoplastic filaments, such as polyethylene, formed into an inverted basket shape so that, when in position, it covers the upper face of the sponge and at least a portion of the sides.

Cover 37 is placed over sponge 35 and the covered sponge is inserted into cup 23. Because the sponge is resilient and normally of greater volume than the cup, it presses the cover outwardly against the inner wall of the cup, helping to hold it in position. The flared sides 27 of the cup, creating a restriction 41 at the top, in cooperation with the force exerted by the sponge as it attempts to return to its normal shape and size, serve to better hold the sponge and cover in place, preventing their slipping out of the cup during use.

The assembled applicator fitting, comprising cup, sponge and cover, is inserted in opening 17. Because the external diameter of the cup 23 near its bottom is greater than that of internal bead 21 on the container, the applicator fitting must be temporarily distorted as it is inserted past the bead. The resilience of the cup causes it to tend to return to normal shape after passing the bead and the snap fit thus resulting holds the fitting in place in the container With cup walls 27 exerting a force against the container.

In the assembly described, the sponge 35 presses against the permeable cover 37 and helps to hold it up and above the flange 25, as illustrated. The shape of the applicator and cover surface may also be regulated by forming the cover before assembly and complementary sponge shapes will assist in maintaining the desired form. However, the most natural shape for the cover to assume, due to the forcesexerted by the restricted sponge, is a slightly bulged or dome-like one, as is illustrated, and this has been found particularly useful in aiding in smoothly applying liquid to various surfaces, particularly to the skin. In addition to helping to shape the cover, the resilience of the sponge also causes a very useful intimate'contacting of sponge and cover so that the sponge acts as a continuous wick, keeping the entire cover'surface moist with liquid to be applied.

In use, the container, together with the applicator, is inverted to allow liquid to flow through opening 31 until absorbent sponge 35 has soaked up its capacity of liquid. The sponge, being in contact with cover 37, wets the outer surface of the applicator and the product may the-n be used to spread the fluid contents as desired. The applicator may be used in an upright position because the sponge holds a supply of liquid, and on contact with the surface to be covered with fluid, compression of the sponge causes more liquid to be readily transported to the cover. After use, to prevent loss of contents by evaporation and also to prevent leakage from accidental inversion of the containers, as in shipping, closure 45, having internal screw thread 47, is screwed tightly into place. Cap closure 45 has a recess 51 to accommodate the projecting applicator and an annular downwardly extending bead 49 which serves as means for pressing resilient flange 25 against top 20 of the container. The force exerted by the head 49 should cause the resilient flange 25 to press tightly against both the cap 45 and bottle container neck 13, conforming to any slight irregularities therein and preventing the leakage of fluid outside the container. It will be seen that the fluid-tight seal does not prevent liquid from wetting the applicator and maintaining it in moist condition, ready for immediate use. As is also clear, should the container be inverted long enough for liquid to fill the cap section, as well as the sponge, merely placing the container upright for a short time before use will facilitate drainage.

Various elements of the invented article have been described with reference to the illustrations showing one embodiment thereof in FIGS. 1-4. Modifications of the apparatus are also within the claims appended hereto and in the following description some of these will be indicated. Also, there will be recited several considerations that should be taken into account when manufacturing a dispensing applicator of this invention.

One should select the materials to be employed in view of their compatibility with the liquid being dispensed. It is known that liquids containing solvents such as lower alcohols tend to leach plasticizer from certain synthetic plastics and foams, causing What may be an undesirable hardening or shrinking, while other plastics may soften and swell in the presence of solvents. Polyurethane sponge is not adversely affected by most liquids comprising aqueous or lower alcoholic media. The tendency of sponge of this material to swell in the presence of alcohols is in its favor in the present article, because the sponge does not soften or coalesce and still maintains its resiliency, even tending to press more against a cover member. Although the urethane plastics, both polyester and polyether types, are preferred open celled sponge materials, other open celled sponges made of other synthetic substances, such as neoprene, regenerated cellulose and so forth, that may be suitable for the application of the liquid, may also be used. Usually the plastic foams will be of low densities, e.g., polyurethane of 28 pounds per cubic foot, but higher density foams are unobjectionable, provided that the sponge is satisfactorily resilient.

The cup of the applicator is preferably a polyolefinic plastic, such as polyethylene or polypropylene, but certain vinyl and other plastics are also suitable. These should be resilient enough to fit into the container neck and still exert a force on the sides, and also possess enough resilience for the flange to be conformed to container and cap to prevent leakage when the package is closed. It has been found that polyethylene of a durometer hardness of about 3040 is ideally suited for the applicator cup, being of satisfactory shape stability and resilience. The opening at the bottom of the cup may be regulated in size to obtain the optimum rate of passage of liquid from the container to the sponge reservoir. If desired, several small openings may be used to distribute the liquid better but this has not been found to be necessary.

The cover for the sponge, the part of the applicator which is in actual contact with the surface to be treated, may be a woven cloth made from monofilament extruded plastic. The cloth should be resilient enough to form a smooth surface, preferably of somewhat dome-like or elevated appearance, in response to the pressure of the sponge, and should resiliently conform to the surface to which liquid is being applied. The openings in the cloth are preferably small enough so that the sponge does not project therethrough into contact with external surfaces. Use of small openings, in conjunction with a sponge having small passages through it prevents dripping of liquid from the applicator when inverted but allows a uniform dispensing flow when applied to a surface to be treated. Instead of a woven cloth, other permeable covers, such as those containing a multiplicity of perforations, passageways or regularly distributed holes may be used. Whether in cloth, film or other form the cover should be smooth enough to glide over the surface being treated, without seizing or binding thereon and without being torn or disrupted by contact with irregularities on the surface. Polyethylene plastic covers slide easily over the skin, even when used as covers for applicators dispensing pre-shave lotions onto bearded skin. In such applications, many uncovered sponges would tend to be torn, resulting in an unsightly applicator surface of uneven application characteristics as well as causing irritation to the skin of the user.

When the material of the cover is a thermoplastic, a woven cloth thereof may readily be heat shaped to desired basket form. Alternatively, monofilament strands may be heat sealed together and heat shaped or they may be molded to final desired form in one operation. In the embodiment of the applicator fitment illustrated in FIGS. 5 and 6, thermoplastic cover 53 is heat sealed to the cup 23, preferably on the upper side of flange 25, after sponge 35 has been inserted in the cup. When so made, the applicator fitment is a single inseparable assembly and cannot inadvertently be pulled apart during careless use. In effecting the heat seal of the cover edge and flange 25, care should be taken to smooth the upper surface of the cover at the sealing flange section so that the sealing means on the cap will close off the flow of liquid and make an effective fluid-tight connection. In FIG. 7, there is shown an applicator fitment like that of FIGS. 5 and 6 but with a microporous polymeric synthetic organic plastic covering 55 heat sealed to cup flange 25 continuously about the flange. As illustrated at 57, heat sealing of the microporous plastic, which the employement of thermoplastics allows, decreases the thickness of the plastic and makes it continuous, producing a more intimate contact of the abutting surfaces to be sealed. Also, heat scaling to a flange or supporting member provides a convenient way of holdin the microporous applicator surface in shape and of strengthening it at the region of sealing. Good sealing and strengthening there are important because sponge 35 subjects the seal to tension as it presses cover 55 upwardly, causing a raising of the center thereof. Also, frictional forces on the cover, as it is moved over a surface to which liquid is applied, might cause a weakened covering to tear at the line of joinder of cover to holding or retaining means.

Microporous cover 55 is made of a material that has been found to be an excellent applicator means, superior to ordinary porous or perforated materials. Preferably, it is made of high pressure polyethylene, which is flexible and resilient, but other polyethylenes, or poly lower alkylenes, e.g., polypropylene, may also be used. Unplasticized polyvinyl chloride, plasticized polyvinyl chloride, vinylidene chloride polymers, e.g., vinylidene chloridevinyl chloride copolymers, may also be employed, as may various other suitable well-known thermoplastics and other synthetic organic plastic materials. The preferred materials are resilient and flexible and feel soft when applied to the skin.

It has been found that the described microporous plastics possess properties which make them highly desirable as applicator surfaces and coverings associated with liquid dispensers. In addition to a soft smooth feel, so important in applying cosmetics, the applicator material allows liquids to penetrate its very fine pores and be transferred to the applicator surface for use, on which surface the liquid forms a thin, often almost invisible even film, which is easily transferred to the skin in a thin continuous film by lightly contacting the skin with the applicator. Although the covering 55 allows ready flow of liquids through it, when it is in place on a dispensing container it Will not allow liquid to drip off the applicator surface, even when the container is inverted. Also, the applicator surface looks solid and continuous, the pores being too small to be seen with the naked eye. Usually, it does not even appear to be Wetted. Because of the small holes, it glides smoothly over the skin and itself feels like smooth skin.

In addition to the above-mentioned advantages, the microporous applicator has been found to transfer liquid laterally, as well as axially through the material. Thus, even coating of the applicator surface is promoted. Also, contrary to what might be considered to be expected, the covering does not tend to dry out and become blocked by dissolved solids even when used to dispense substantial quantities of dissolved solids in volatile solvents, as in antiperspirant compositions.

These recited advantages of the microporous coverings of this invention are attributable to the microporous structure thereof. It has been found that the average size of the cellular openings in the material should be between about 5 and .120 microns, preferably between 50 and 100 microns across the cell and the cells or gas volume should be 60 to 90%, preferably 70 to 85% of the volume of the covering. When cell size and proportions of cells are in these ranges, the dispensing covering operates in the manner described above to satisfactorily dispense and apply liquids. If smaller cells are present, flow will be inhibited and if they are larger, they will be visible, the covering will not have such good tactile properties and droplets of liquid may form and fall from the applicator when the container is inverted, nullifying its leak-proof character. Similar considerations apply to variations in the proportions of cell and plastic outside the ranges given, the greater the proportion of cell space, the easier liquid is transferred through the covering. Also, above an upper limit of cell volume, the material will be seriously weakened.

Using cell sizes and volume proportions given, one may dispense alcoholic solutions and aqueous alcoholic solutions easily, when the covering is 5 to 200 mils thick, al though thinner materials, to 100 mils may be preferable. For example, ethanol will flow to the applicator surface under very low pressures, as little as 0.1 millimeter of mercury. Usually no more than 25 millimeters of mercury will be impressed and a more limited useful range is from 0.5 to 10 millimeters, generally the range of heights of liquid in a bottle. Microporous plastics of the type required by this invention are of only recent availability and some had to be made especially for use in the present product. They may be made by any suitable method but those obtained by mixing a finely divided non-plastic substance with the plastic and subsequently removing the non-plastic to create cells are considered to be the best available at the present. An example of such a method is a process in which finely divided starch, such as corn or potato starch, is mixed with a plastic, e.ig., polyethylene, until it is dispersed substantially uniformly, after which the starch particles are swelled as by contact with alkali. The swollen particles stretch the plastic and cause some interconnecting of starch volumes. Then the starch is treated, as by acid, to hydrolyze it to water solubility, after which it is leached out by water, leaving a series of interconnecting voids or cells, somewhat resembling bread structure, although on a much smaller scale. The plastic may be solidified, rolled or deposited as a sheet or layer at any convenient stage in the process. The product resulting is smooth and regular and is of suhlcient strength to make it acceptable for applicator use. Of course, the cells formed need not be and usually are not perfectly globular. Instead, they are somewhat irregular when examined microscopically, although the average size across voids or cells will be within the ranges given. Also, even if the cells are very irregular, the liquid transfer properties of the microporous plastic are dependent on the restrictions in paths the liquid follows through the pores. It has been found that the pores may be fine enough to block solid particles which are within the range of 5 to 50 microns across.

'In FIGS. 8-43 is illustrated another dispensing applicator, closely related to those of FIGS. 1-7. In FIG. 8 numeral 59 designates a glass container of liquid 61 having a neck 63 with an external screw thread to match that in cap 65. At the top of the neck is a peripheral bead 67 with depression 69 below it. Means are provided in the container interior to support a reservoir material 711, which may be a sponge, such as a polyurethane sponge with microscopic cells. After insertion of the sponge into place, a retainer 73, to which a microporous covering '75 is fastened, as by cementing or heat sealing, 1s snap fitted onto the container, covering and controllably closing the dispensing opening thereof. For shipping, cap 65 is screwed into place but, as will be seen from FIGS. 9-13, the cap does not have to include means for sealing against a flange member of the applicator fitment, as shown in FIGS. 1-7. Sealing may be against a peripheral portion 77 of the upper surface of the retainer or may not be necessary at all, since the snap fit engagement of the retainer and container bead is fluid-tight. Instead of a snapor frictional press-fit, other means of fastening the retainer to the container neck may be employed, such as conventional threaded joinders or cementing.

In FIGS. 9 and 10, details of a means of holding and supporting reservoir sponge 71 are illustrated. Container 59 has a shoulder top 79 from which rises neck 63 with threads 81. Snap-fit head 67 extends out from the upper annular top 83 of the bottle. Molded into the bottle neck isa bowl-shaped inner wall 85 which is smaller at the bottom than the sponge 71 so that the sponge will be supported thereby. Hole 87 allows the passage of liquid to be dispensed to the sponge when the container is inverted.

In FIGS. 11-13 details of the microporous covering and retainer are shown. In FIG. 11 the microporous covering is held onto container 59 by retainer 73. FIG. 13 illustrates an enlarged section of the retained microporous cover, numeral 85 designating some of the cells or voids in the material. In FIG. 12 retainer 73 is sealed to applicator covering 75 at 87, where the seal is effected between the upper surface of the peripheral portion of the porous material and the lower portion of inwardly extending circular flange 89 of the retainer. It is preferred to have the seal a continuous circular heat seal. As shown, the covering is sealed under flange 89 but it may also be held to the upper surface thereof 77, if desired. In either case, it is preferred to have the retainer made of a suitable thermoplastic material and it is especially desirable for it to be the same as the thermoplastic of the microporous cover. Snap flange 91 completes the retainer and holds it tightly to the container by means of snapping over bead 67.

As described, the microporous covering is in contact with a reservoir sponge 71', which may be moistened with liquid to be applied and then acts as a reservoir to keep the microporous covering moist. The sponge also presses the cover upwardly and causes it to assume, a domelike shape, higher at the middle than on the periphery, which facilitates application of the liquid to surfaces to which it may be applied. Such shaping of the cover can also be effected by heat sealing while the cover is heldarcuate, the seal perpetuating the distortion. Although the sponge reservoir performs the useful functions recounted, the present dispenser with the special microporous applicator materials does not require the presence of the sponge for it to be operative. The microporous structure itself is suificient to prevent dripping of liquid, even of thin volatile liquids, such as ethanol, without the aid of a sponge bafiie. Thus, although illustrated with a sponge element, it should be understood that they invented applicator in which the microporous covering is employed is not limited to having a sponge reservoir present. Of course, it is desirable to have some means for holding liquid in contact with the microporous covering so that the supply thereof will not be exhausted during application, even if the container is employed in an upright position. Also, it is useful to have a sponge or other backing means to support the cover material. Finally, the sponge will act as a baffie to decrease any abrupt pressures applied to the cover and protects it in this respect. Still, with the sponge removed, the applicator works satisfactorily; it merely requires replenishment by liquid more frequently.

In FIG. 14 is shown a novel structure in which microporous plastics of different microporosities are utilized together to produce a cover of desired liquid transfer characteristics. Thermoplastic retainer means 73 is heat sealed to microporous covering 93 at 87 and that covering is heat sealed to another microporous circular cover 95 at annular area 97. Preferably, the upper cover 93 has pores or cells smaller than those of the lower cover, although this is not necessary. Both covers are microporous materials like those previously described. It will be seen that the use of two or more cover sheets allows accurate control of liquid transfer rates without the necessity for producing a special microporous cover for each different type of liquid to be dispensed. Also, the lower cover supports the upper one and acts as a supplemental reservoir.

In FIGS. 15 and 16 a dispensing applicator of the squeeze-bottle type is shown, with a microporous thermoplastic cover heat sealed to the top thereof, closing the dispensing opening. A resilient thermoplastic, e.g., polyethylene, container 9 has a neck 101, onto the top of which a microporous thermoplastic, e.g., polyethylene, covering 103 is peripherally heat sealed. It will be observed that the heat sealed peripheral area extends only across part of the neck, resulting in a structure in which the microporous material is less likely to be torn apart when applied carelessly. Screw threads 105 are provided on container neck 161 to hold a sealing cap, which may abut the heat sealed portion of covering 103 and/ or the porous parts thereof.

To use any of the present dispensing applicators one needs only to invert it to all-ow liquid to permeate the microporous covering. The liquid will not drip off the cover but will be removable therefrom in a thin continuous film when the cover is applied to a surface and is lightly moved along it. Usually, the head of liquid in the dispensing container will be suflicient to cause it to flow to the applicator surface and to dampen that surface. However, flow rate can be increased by the use of higher pressures and finer microporous structures can be utilized when means are present to increase the liquid pressure on the microporous cover. Thus, a resilient bottle, such as that of FIGS. 15 and 16, will be inverted for use and may be squeezed until the pressure is such as to result in the desired liquid flow.

In discussing flow properties of liquids through the present microporous materials, it is appropriate to mention the auxiliary action of wetting agents. Because flow through small passageways, such as those in the present covers, is dependent on viscosity and surface tension of the flowing liquid with respect to the material of the microporous material, the reduction of viscosity and/ or the decrease in surface tension will increase flow rate. Thus one may include agents for these purposes in the liquid being dispensed. Also, it has been found desirable to treat the microporous materials which are hydrophobic, such as polyethylene, with a solution of synthetic organic surface active agent or wetting agent to facilitate passage of water through them. Such treament may be effected by adding a Wetting agent such as a nonionic detergent, e.g., a polyoxyalkylated alkanol, or an anionic surface active agent, e.g., lower alkyl naphthalene sulfonate, to the leaching solution for removing the hydrolyzed starch. Alternatively, the microporous plastic may be subjected to a post-treatment bath in a solution of wetting agent.

Dispensing applicators in accordance with this invention have been made and tested so that the advantages thereof are fully established. The dispenser of FIGS. 1-6 requires a sponge or other absorbent material adja cent to the covering to prevent dripping of liquid when the applicator is held inverted. Although desirable, such absorbent is not necessary in the structures of FIGS. 7- 16 because the microporous covering material, itself, prevents leakage except when it is intentionally applied to a surface. A specific example of a material employed in an applicator like that of FIG. 8 is microporous plastic made by the ESE-Reeves Corporation, Yardley, Pennsylvania, and designated by them as their 25 mil 4:1 N/P polyethylene. This resilient material has a total porosity (gas or void Volume) of appears to the naked eye to be solid on its surface and is reported to have cell sizes all between 8 and 12 microns. It was successfully employed in dispensing an alcoholic shaving lotion, comprising lower alkanol and skin treating oils. The lotion did not drip when the applicator was inverted, even when the sponge was removed. Similar applicators, made with microporous materials of 60% to porosity and averaging from 5 to 120 micron cell size also transfer liquid satisfactorily. For aqueous solutions one usually employs those materials which have cells of 20 to 120 microns, preferably 50 to microns. Of course, the material should be thick enough to be of suflicient tensile strength to be practicable, in View of the porosity and cell size.

The heat sealing of microporous thermoplastic material to solid thermoplastic did not present any great difficulty although it might have been expected to weaken the material, especially at the points Where fused thermoplastic and porous thermoplastic meet. Conventional sealing temperatures and pressures were used and an effective strong seal was obtained, which was not weakened by repeated contact with the solvent of the liquid being dispensed.

The invention has been described with respect to several embodiments thereof. It is not limited to the specific articles illustrated and discussed but includes all structures within the scope of the claims and equivalents thereof.

This application is a continuation-in-part of my copending application S. N. 13,751 for Dispensing Applicator, filed March 9, 1960, now abandoned.

What is claimed is:

1. A dispensing applicator for free-flowing liquid comprising a container for liquid to be dispensed, a walled opening at the top thereof, a flanged plastic cup fitting in the container through the opening, with the flanged open end facing upwardly and with the flange above the container wall that defines the opening, the side Walls of which cup, when relaxed, being at least in part of greater width than the internal distance between a corresponding part of the wall of the container opening past which the cup is inserted, the inner wall of said walled opening tapering inwardly at the top thereof, the plastic cup being sufficiently resilient and flexible to allow insertion in the container and to maintain force against the container to hold the cup in place therein, the cup bottom having an opening for passage of liquid to the cup from the container, a resilient open celled sponge in the cup for absorbing liquid prior to application, a flexible cover for the sponge, containing a multiplicity of distributed openings through which liquid may pass to a surface to which it is to be applied, the sponge being of sufficient size and resilience to press the cover upwardly and maintain it in shape above the flange so that the cover may yieldingly contact the surface to which the dispensed liquid is to be applied, and a removable closure, including means for pressing the flange of the cup tightly against the top of the Wall that defines the container opening and for holding the flange against the container and the closure in fluid-tight engagement when the applicator is not in use.

2. A dispensing applicator for free-flowing liquid comprising a container for liquid to be dispensed, a substantially cylindrically Walled opening at the top thereof with an external thread, a circularly flanged plastic cup fitting in the container through the opening with the flanged open end facing upwardly and with the flange above the substantially cylindrical container wall that defines the opening, the side walls of which cup, when relaxed, being at least in part of greater external diameter than the internal diameter of a part of the container opening wall past which the cup is inserted, the inner wall of said walled opening tapering inwardly at the top thereof, the plastic cup being sufiiciently resilient and flexible to allow insertion in the container and snap fitting in place therein with the cup maintaining lateral force against the container inner wall after fitting in place, the cup bottom having an opening for passage of liquid to the cup from the container, a resilient open celled sponge in the cup for absorbing and holding liquid prior to application, a flexible plastic cloth cover for the sponge, containing a multiplicity of evenly distributed openings through which liquid may pass to a surface to which it is to be applied, the sponge being of suflicient resilience and size, greater than the cup volume, during use, to press the cover upwardly and maintain it in desired shape above the cup flange so that the cover may yieldingly contact the surface to which the dispensed liquid is to be applied, and a removable threaded cap closure including means for pressing the flange of the cup tightly against the top of the wall that defines the container opening and for holding the flange against the container and the closure in fluid-tight engagement when the cap closure is screwed tightly against the container.

3. A dispensing applicator according to claim 2 in which the cover for the sponge is heat sealed to the upper surface of the cup flange, the heat sealed material being sufficiently resilient, smooth and continuous so that, on closing the cap closure tightly in place, the flange will be held in fluid-tight engagement with the cap closure and against the container, preventing leakage and evaporation of liquid when the dispensing applicator is not in use.

4. A dispensing applicator according to claim 2 in which the open celled sponge is of a plastic material free of plasticizer, which retains its resiliency and is nonshrinking in the presence of lower alcoholic solvents, and the cup and cover are of a thermoplastic material which is of suflicient rigidity and dimensional stability in the presence of lower alcoholic solvents to press the cup tightly against the walls defining the container opening and hold the applicator in place therein, while also being flexible and resilient enough in the monofilarnent form, in which it is woven into the cover, to be temporarily yieldingly deformable to accommodate the applicator to irregularities in the surface to which material is being applied, thereby promoting uniform coverage of said surface.

5. A dispensing applicator according to claim 4 in which the open celled sponge is of polyurethane and the cup and cover are of polyethylene.

6. A dispensing applicator for free-flowing liquid comprising a container for liquid to be dispensed, a substantially cylindrically walled opening at the top thereof with an external thread and an internal restricting bead, a circularly flanged plastic cup, which flares outwardly at the bottom, fitting in the container through the opening and snapping past said internal restricting head, with the flanged open end of said cup facing upwardly and with the flange above the substantially cylindrical container wall that defines the opening, the side walls of which cup, when relaxed, being at least in part of greater external diameter than the internal diameter of a part of a container opening wall past which the cup is inserted, the plastic cup being sufficiently resilient and flexible to allow insertion in the container and snap fitting in place therein with the cup maintaining lateral force against the container inner wall after fitting in place, the cup bottom having an opening for passage of liquid to the cup from the container, a resilient open celled sponge in the cup for absorbing and holding liquid prior to application, a flexible plastic cloth cover for the sponge containing a multiplicity of evenly distributed openings through which liquid may pass to a surface to which it is to be applied, said plastic cloth cover being shaped like an inverted basket, with a top that projects past the cup flange and with side walls extending downwardly into the flanged cup, said sponge being of suificient resilienceand size, greater than the cup volume, during use, to press the 10 cover upwardly and maintain it in desired shape above the cup flange so that the cover may yieldingly contact the surface to which the dispensed liquid is to be applied and urging the sides of said cover outwardly against the cup, thereby holding the cover in place in the cup during normal usage and subjection to the frictional forces encountered in sliding of the applicator across the surface to which liquid is to be applied, and a removable threaded cap closure including means for pressing the flange of the cup tightly against the top of the wall that defines the container opening and for holding the flange against the container and the closure in fluid-tight engagement when the cap closure is screwed tightly against the container.

7. A dispensing applicator for liquid comprising a container for liquid to be dispensed, a walled opening at the top thereof, a resilient flanged cup fitting in the container through the opening, with the flanged open end facing upwardly and with the flange above the container Wall that defines the opening, the cup bottom having an opening for passage of liquid to the cup from the container, and the cup being wider at the bottom thereof than adjacent the flange, the inner wall of said walled opening tapering inwardly at the top thereof, a resilient absorbant material in the cup for absorbing liquid prior to application, a cover for the absorbant material containing a multiplicity of distributed openings through which liquid may pass to a surface to which it is to be applied and a removable closure, including means for pressing the flange of the cup tightly against the top of the wall that defines the container opening and for holding the flange against the container and the closure in fluid-tight engagement when the applicator is not in use.

8. A dispensing applicator for liquid comprising a con tainer for liquid to be dispensed, a walled opening at the top thereof, a resilient flanged cup fitting in the container through the opening, with the flanged open end facing upwardly and with the flange above the container wall that defines the opening, the cup bottom having an opening for passage of liquid to the cup from the container and the cup being wider at the bottom thereof than adjacent the flange, a resilient absorbent material in the cup for absorbing liquid prior to application, a microporous polymeric synthetic organic plastic cover for the cup and the resilient material therein, the cover being of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of an average size between 5 and 120 microns across the cell and comprising 60 to of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing indirect passageways therethrough for liquids to flow from the container and absorbent to the applicator surface, the cellular openings of the size described being such that ethanol flows to the applicator surface under a pressure between 0.1 and 25 millimeters of mercury, forms a liquid film on the applicator surface, 1s retained thereon when the covered container is inverted and may be removed by light contact with surfaces to 'which the applicator is applied, thereby forming smooth continuous films thereon, and a removable closure, including means for pressing the flange of the cup tightly against the top of the wall that defines the container openlng and for holding the flange against the container and the closure in fluid-tight engagement when the applicator is not in use.

A dispensing applicator for liquid comprising a container for liquid to be dispensed, a walled opening at the top thereof, a resilient flanged thermoplastic cup fitting in the container through the opening, with the flanged open end facing upwardly and with the flange above the container Wall that defines the opening, the cup bottom having an opening for passage of liquid to the cup from the container and the cup being wider at the bottom thereof than adjacent the flange, a resilient absorbent material in the cup for absorbing liquid prior to application,

a microporous polymeric synthetic organic thermoplastic cover for the cup and the resilient material therein, the cover being of a thickness between and 260 mils, being heat sealed to the cup, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of an average size between 5 and 120 microns and comprising 60 to 90% of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways therethrough for liquids to flow from the container and absorbent to the applicator surface, form liquid films on the applicator surfaces, be retained thereon when the covered container is inverted and be removable by light contact with surfaces to which the applicator is applied, thereby forming smooth continuous films thereon, and a removable closure, including means for pressing the flange portion of the cup tightly against the top of the wall that defines the container opening and for holding it against the container in fluid-tight engagement when the applicator is not in use.

10. A dispensing applicator for liquid comprising a container for liquid to be dispensed, a walled opening therein, a microporous polymeric synthetic organic plastic cover for the opening, means for holding the cover to the container in fluid-tight relationship so that passage of liquid between container and cover will be prevented; a resilient absorbent material and means for holding said material so that it contacts the interior of the cover and is communicable with the liquid to be applied, the microporous synt etic plastic cover being of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 5 and 120 microns and comprising 60 to 90% of the volume of the cover, so that the applicator surface appears tobe solid and continuous, said cover providing passageways therethrough for liquids to flow from the container and absorbent to the applicator surface, form liquid films on the applicator surfaces, be retained thereon when the covered container is inverted and also be removable therefrom by light contact with surfaces to which the applicator is applied, thereby forming smooth continuous films thereon.

11. A dispensing applicator for liquid comprising a container for liquid to be dispensed, which container has a circular opening therein, a microporous polymeric synthetic organic thermoplastic cover for the opening, a thermoplastic ring, to which the microporous cover is heat sealed continuously around the ring so as to prevent leakage of liquid between ring and cover and means for holding the thermoplastic ring tightly to the container, the microporous synthetic plastic covering being of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 5 and 120 microns and comprising 60 to 90% of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways therethrough for liquids to flow from the container to the applicator surface, form liquid films on the applicator surfaces, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces to which the applicator is applied, thereby forming smooth continuous films thereon.

12. A dispensing applicator for liquid comprising a container for liquid to be dispensed, which container has an opening therein, and a microporous polymeric synthetic organic plastic cover for the opening, the cover being of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 5 and 120 microns and comprising 60 to 90% of the volume of the cover, providing passageways therethrough for liquids to flow from the container to the applicator surface, form liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces to which the applicator is applied, thereby forming smooth continuous films thereon.

13. A dispensing applicator fitment for dispensing a liquid from a container through a dispensing opening therein and applying the liquid to a surface in a smooth continuous film which comprises a microporous polymeric synthetic organic thermoplastic cover for the dispensing opening of the container, which cover is of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 5 and 120 microns and comprising 60 to of the volume of the cover, providing passageways therethrough for liquids to flow from the container to the applicator surface, form liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces, and a thermoplastic retainer, heat sealed to the microporous cover so as to prevent leakage of liquid between retainer and cover, the retainer also being of such construction including holding means, to hold fluid-tightly to a dispensing container, thus causing dispensing of liquid through the dispensing opening to be through the microporous cover.

14. A dispensing applicator fitment for dispensing a liquid from a container through a dispensing opening therein and applying the liquid to a surface in a smooth continuous film which comprises a microporous polymeric synthetic organic thermoplastic cover for the dispensing opening of the container, which cover is of a. thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 5 and microns and comprising 60 to 90% of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways therethrough for liquids to flow from the container to the applicator surface, form liquid films on the applicator surface, be retained theron when the covered container is inverted and be removable therefrom by light contact with surfaces, a reservoir under the cover for holding liquid adjacent thereto, and a thermoplastic retainer, heat sealed to the microporous cover so as to prevent leakage of liquid between retainer and cover, the retainer also being of such construction, including holding means, to hold fluid-tightly to a dispensing container, thus causing the dispensing of liquid through the dispensing opening to be through the microporous cover.

15. A dispensing applicator for liquid comprising a resilient thermoplastic container having an opening therein and, heat sealed over the opening, a microporous polymeric synthetic organic thermoplastic cover of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 20 and 120 microns and comprising 60 to 90% of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways therethrough for liquids to flow from the container to the applicator surface, form liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces, the microporous cover being fused to the container continuously about the opening therein, thus preventing leakage of liquid between container and cover.

16. A dispensing applicator for dispensing a liquid from a container through a dispensing opening therein and applying the liquid to a surface in a smooth continuous film, which comprises a pair of microporous polymeric synthetic organic coverings for the dispensing opening of the container, of which one is an outer applicator covering and another is an inner covering, the coverings being in contact with each other and both being of a thickness between and 100 mils, having distributed therethrough a multiplicity of interconnected cellular openings of a size numerically and meanly averaging between 5 and 120 microns and comprising 60 to 90% of the volume of the coverings, the outer covering having cellular openings averaging smaller than those of the inner covering, the combination of coverings being such that the applicator surface of, the outer applicator covering appears to be solid and continuous, passageways are provided through the covering for liquids to flow from the container to the applicator surface, the combination of the cellular Openings in the coverings of the sizes described being such that liquids flow from the container to the outer applicator surface, form films on the applicator surface, are retained thereon when the covered container is inverted and are removable therefrom by light contact with surfaces.

17. A dispensing applicator for dispensing a liquid from a container through a dispensing opening therein and applying the liquid to a surface in a smooth continuous film which comprises a microporous polymeric synthetic organic thermoplastic cover for the dispensing opening of the container, which cover is of a thickness between 5 and 200 mils, having an applicator surface and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging between 5 and 120 microns and comprising 60 to 90% of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways therethrough for liquids to flow from the container to the applicator surface, form liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces, means, including a heat seal, for holding the microporous cover to the container and means for holding the cover raised so that a central portion thereof curvedly projects further from the container opening than an outer portion.

18. A dispensing applicator for liquid comprising a container for liquid to be dispensed, which container has an opening therein and a microporous polymeric synthetic organic plastic cover for the opening, the cover being of a thickness between and 50 mils, having an applicator surface of tactile properties like those of smooth skin and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging from 50 to 100 microns and comprising 70 to 85% of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways therethrough for liquids to flow from the container to the applicator surface, form thin liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces to which the applicator is applied, thereby forming smooth continuous films thereon.

19. A dispensing applicator for liquid comprising a container for liquid to be dispensed, which container has an opening therein and a microporous polyethylene cover for the opening, the cover being of a thickness between 10 and 50 mils, having an applicator surface of tactile properties like those of smooth skin and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging from 50 to 100 microns and comprising 70 to 85% of the volume of the cover, so that the applicator surface appears to be solid and continuous, said cover providing passageways thereid through for liquids to flow from the container to the applicator surface, form thin liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces to which the applicator is applied, thereby forming smooth continuous films thereon.

20. A dispensing applicator fitment for dispensing a liquid from a container through a dispensing opening therein and applying the liquid to a surface in a smooth continuous film which comprises a microporous polymeric synthetic organic thermoplastic cover for the dispensing opening of the container, which cover is of a thickness between 10 and mils, having an applicator surface of tactile properties like those of smooth skin and having distributed through the cover a multiplicity of interconnected cellular openings of a size averaging from 50 to 100 microns and comprising to of the volume of the cover, so that the applicator surface appears to be solid and continuous, said'cover providing passageways therethrough for aqueous and alcoholic liquids to flow from the container to the applicator surface, form thin liquid films on the applicator surface, be retained thereon when the covered container is inverted and be removable therefrom by light contact with surfaces, and a thermoplastic retainer, heat sealed to the microporous cover so as to prevent leakage of liquid between retainer and cover, the retainer also being of such construction, including holding means, to hold fluid-tightly to a dispensing container, thus causing dispensing of liquid through the dispensing opening to be through the microporous cover.

21. A dispensing applicator fitment according to claim 20 in which the cover is a microporous polyethylene material prepared by mixing finely divided starch with polyethylene, dispersing the starch substantially uniformly therein, contacting the dispersion with alkali and swelling the starch particles, contacting the dispersion with acid and hydrolyzing the starch and leaching the starch from the polyethylene matrix by contacting it with water, to produce a microporous structure.

22. A method of dispensing liquids in a smooth continuous film which comprises placing the liquid in contact with a microporous polymeric synthetic organic plastic material of a thickness between 5 and 200 mils, said micro polymeric synthetic organic plastic material with which said liquid is in contact having distributed throughout the material a multiplicity of interconnected cellular openings of a size averaging between 5 and 120 microns and comprising 60 to of the material volume, so that the applicator surface appears to be solid and continuous, exerting a pressure of 0.1 to 25 millimeters of mercury on the liquid at the surface of the microporous plastic material, to cause the liquid to pass through the cellular openings to dampen the applicator surface and form a smooth, thin continuous liquid film thereon and applying the applicator to a surface to be coated and moving it along said surface with light pressure to deposit a smooth thin film of liquid on the surface.

References Cited in the file of this patent UNITED STATES PATENTS 2,594,729 Carvalho Apr. 29, 1952 2,853,727 Nadai Sept. 30, 1958 2,853,728 Nadai Sept. 30, 1958 2,961,677 Zecchini Nov. 29, 1960 FOREIGN PATENTS 563,932 Belgium July 14, 1958 873,178 Great Britain July 19, 1961 iiiW UNITED STATES PATENT OFFICE 7 CERTIFICATE OF CORRECTION Patent No c. 3 ,133 ,309 May 19; 1964 Gilbert Dewayne Miles It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 5, line 72, for "microscopic" read macroscopic column 6, line 45, after "assume" strike out the comma; column 11, line 52, for "covering" read M cover column 12, line 43, for "theron" read thereon column 13, line 13, for "covering" read H coverings g,

Signed and sealed this 24th day of August 1965c (SEAL) A nest:

ERNEST W SWIDER EDWARD J BRENNER Attesting Officer Commissioner of Patents 

12. A DISPENSING APPLICATOR FOR LIQUID COMPRISING A CONTAINER FOR LIQUID TO BE DISPENSED, WHICH CONTAINER HAS AN OPENING THEREIN, AND A MICROPOROUS POLYMERIC SYNTHETIC ORGANIC PLASTIC COVER FOR THE OPENING, THE COVER BEING OF A THICKNESS BETWEEN 5 AND 200 MILS, HAVING AN APPLICATOR SURFACE AND HAVING DISTRIBUTED THROUGH THE COVER A MULTIPLICITY OF INTERCONNECTED CELLULAR OPENINGS OF A SIZE AVERAGING BETWEEN 5 AND 120 MICRONS AND COMPRISING 60 TO 90% OF THE VOLUME OF THE COVER, PROVIDING PASSAGEWAYS THERETHROUGH FOR LIUQIDS TO FLOW FROM THE CONTAINER TO THE APPLICATOR SURFACE, FROM LIQUID FILMS ON THE APPLICATOR SURFACE, BE RETAINED THEREON WHEN THE COVERED CONTAINER IS INVERTED AND BE REMOVABLE THEREFROM BY LIGHT CONTACT WITH SURFACES TO WHICH THE APPLICATOR IS APPLIED, THEREBY FORMING SMOOTH CONTINUOUS FILMS THEREON. 